Flame Resistant Fabrics Having Improved Resistance to Surface Abrasion or Pilling and Methods for Making Them

ABSTRACT

Flame resistant fabrics and garments that have improved resistance to pilling and/or abrasion are disclosed. The fabrics, the fibers or yarns that make up the fabrics, or garments made from the fabrics are treated with a finish composition that is applied to the fibers, yarns, fabrics, or garments and then cured. The finish composition increases the resistance to pilling and/or abrasion of the fibers, yarns, fabrics, or garments. The finish composition includes a polymeric abrasion resistance aid, an alkylfluoropolymer, a polyethylene, and a wetting agent.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.12/348,789, filed Jan. 5, 2009 entitled “Flame Resistant Fabrics HavingImproved Resistance to Surface Abrasion or Pilling and Methods forMaking Them”, which claims the benefit of U.S. Provisional ApplicationNo. 61/019,002, filed Jan. 4, 2008 and U.S. Provisional Application No.61/107,582, filed Oct. 22, 2008, all of which are incorporated herein byreference.

FIELD OF THE INVENTION

The present invention relates to flame resistant fabrics that areresistant to surface abrasion and/or pilling, to novel finishcompositions for fabrics that impart abrasion and/or pilling resistance,and to methods for imparting abrasion and/or pilling resistance.

BACKGROUND

Many occupations including, but not limited to, firefighting, emergencyresponse, search and rescue, and military service, may require exposureto extreme heat and/or flames. To avoid being injured while working insuch conditions, individuals typically wear protective garmentsconstructed of special flame resistant materials designed to protectthem from both heat and flames. These protective garments include, forexample, garments worn by firefighters, which are commonly referred toin the industry as turnout gear. Turnout gear can include variousgarments including coveralls, trousers, and jackets. These garmentstypically include several layers of material such as an outer shell thatprotects the wearer from flames, a moisture barrier that prevents theingress of water into the garment, and a thermal barrier that insulatesthe wearer from extreme heat. Other types of protective garments areworn by individuals such as petrochemical workers, electrical workers,those engaged in military service, and others who require protectionfrom extreme heat and/or flames.

Some individuals including, but not limited to, emergency personnel suchas firefighters and other first responders, are not only exposed toextreme heat or flames, but are also exposed to water. In thoseinstances it would be desirable for a flame resistant fabric to alsohave water repellant properties. Thus, turnout gear and other protectivegarments may include woven fabrics formed of one or more types of flameresistant fibers, and the fabrics may also have water repellantproperties.

Protective garments must withstand flame, excessive heat, and abrasion,and in many instances they are constructed of a flame resistant materialthat is both strong and durable. These protective fabrics are expensive,so durability of the fabrics is important. Abrasion refers to thewearing away of any part of a material by rubbing against anothersurface. While flame resistant fibers will retain their flame resistanceeven if the fabric becomes abraded, a protective fabric that becomesabraded may lose other protective properties such as water repellency.An abraded garment may not provide the protection needed by afirefighter, emergency responder, or other individual. Therefore, if aprotective garment becomes abraded, that garment must be replaced.Garments having increased abrasion resistance would need to be replacedless frequently than conventional protective garments. A fabric'sresistance to abrasion can be measured by various test methodologies andequipment such as the test procedures described by ASTM standards D3886and D3884.

Many protective fabrics, including those using spun yarns, filamentyarns, or combinations thereof can have a tendency to pill. “Pills” arerelatively small balls of entangled fibers that can form on the surfaceof a protective fabric. The pills are held to the surface of theprotective fabric by one or more fibers comprising the fabric. Whilemost fabrics pill, the protective fabrics of the present invention aremade of strong fibers which hold onto the pills more tightly than manyother fibers. Thus, pills that form on these protective fabrics tend tobuild up on the fabrics. Such pills can accumulate over time orotherwise increase in number on the surface of the fabric causing anotherwise smooth surface to appear worn or in extreme cases unsightly.In some instances, the unsightly appearance of a protective fabric maycause the associated garment to be considered inferior in quality andmay discourage a user from using the garment. In many instances, thegarment may be replaced prematurely even though the fabric of thegarment can still provide suitable protection for the user. A fabric'sresistance to pilling can be measured by various test methodologies andequipment, such as a random tumble pilling tester and the testprocedures described by ASTM standard D3512.

Conventional techniques to reduce the tendency of fabrics to pill useparticular yarns with mechanical twisting of the yarns, such as air jetspun yarns. However, some fibers, including some fibers used in thefabrics of the present invention, cannot be spun by air jets.Furthermore, protective garments made from air jet spun yarns can stillbe prone to pilling since entangled fibers remain and can form pills onthe surface of such fabrics.

It is known in the art to treat fabrics with finishes where the finishesimpart a particularly useful property to the fabric. For example, someprior art finishes are water repellant finishes that include analkylfluoropolymer and other optional additives such as a blockedisocyanate crosslinker, paraffinic waxes, and the like. Other prior artfinishes include a moisture management finish which includes softeners,permanent press resins and hydrophilic polymers to impart fabric andfiber hydrophilicity. In either case, fabrics exposed to rigorousphysical abrasion tend to show yarn breakage, formation of pills, orboth depending on the exact construction and fiber blend used in thefabric.

Prior art finish compositions may also provide some resistance toabrasion and/or pilling. As an example, a composition including awetting agent, one or more fluoropolymers, a wax fluorochemicalextender/water repellant, a melamine formaldehyde resin, and acrosslinking agent has been used. This finish composition was developedand applied to fabrics to impart water repellency that was more durablethan the water repellency imparted by previously known formulations.This finish imparts some resistance to abrasion compared to untreatedfabrics, but fabrics treated with this finish are still fairly easilyabraded. For example, these fabrics only withstand about 500 Taberabrasion cycles before a first thread break when tested in accordancewith ASTM D3884, using H-18 wheels and a 500 g load on each wheel.

There remains a need for fabrics and protective garments with improvedresistance to surface abrasion and/or pilling.

Accordingly, it is desirable to provide a finish composition capable ofimparting such improved resistance to abrasion and/or pilling to avariety of fabrics. It is further desirable to provide flame resistantfabrics and protective garments with improved surface abrasion and/orpilling resistance. Finally, it is desirable to provide flame resistantand water repellant fabrics and protective garments with improvedsurface abrasion and/or pilling resistance.

SUMMARY OF THE INVENTION

The above mentioned objectives are accomplished by embodiments of thepresent invention.

One embodiment of the present invention is a fabric that has improvedresistance to surface abrasion and/or pilling over prior art fabrics.One preferred embodiment of the present invention is a protective fabricthat includes a composition of flame resistant fibers, wherein thefibers or the fabric has been treated with a novel finish composition,and wherein the protective fabric has improved resistance to surfaceabrasion and/or pilling over untreated protective fabrics and overfabrics treated with prior art finish compositions.

Another embodiment of the invention is a protective garment made from afabric that includes a composition of flame resistant fibers, whereinthe protective garment has improved resistance to pilling and/or surfaceabrasion over prior art protective garments.

Further embodiments of the invention are protective fabrics and garmentswith improved resistance to surface abrasion and/or pilling wherein thefabrics and garments include a composition of flame resistant fibers andwherein the fabrics and garments further have water repellantproperties.

Another embodiment of the present invention is a novel finishcomposition that may be applied to fibers, fabrics, or garments and thatimparts abrasion and/or pilling resistance to those fibers, fabrics, andgarments. In one embodiment, the fibers, fabrics, or garments are flameresistant. In one embodiment the novel finish composition comprises atleast a polymeric abrasion resistance aid, an alkylfluoropolymer, apolyethylene, and a wetting agent. This composition improves upon priorart compositions by improving the abrasion and/or pilling resistance offabrics treated with the composition. Tests show that fabrics treatedwith finish compositions according to the present invention showimproved resistance to abrasion and/or pilling compared to untreatedfabrics or fabrics treated with prior art finish compositions.

Still other embodiments of the invention are methods for impartingimproved resistance to surface abrasion and/or pilling to fabrics orgarments. These methods include the steps of applying the novel finishcomposition to a fiber, a yarn, a fabric comprising a plurality offibers or yarns, or a garment and curing the finish composition. Themethods provide fabrics and garments that have improved resistance toabrasion and pilling over fabrics and garments that have not beentreated according to these methods.

Other systems, methods, processes, devices, features, and advantagesassociated with the fabrics and garments described herein will be orwill become apparent to one with skill in the art upon examination ofthe following drawings and detailed description. All such additionalsystems, methods, processes, devices, features, and advantages areintended to be included within this description, and are intended to beincluded within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention can be better understood with reference to thefollowing drawings. The components in the drawings are not necessarilyto scale.

FIG. 1 illustrates a partial cut-away view of a protective garment.

FIG. 2 illustrates the improved abrasion resistance of a 60/40para-aramid/PBI fabric treated with a finish composition consistent withthe present invention as compared to a sample of the same fabric treatedwith a known finish composition.

FIG. 3 illustrates the improved abrasion resistance of a 60/40para-aramid/PBI fabric treated with a finish composition consistent withthe present invention as compared to a sample of the same fabric treatedwith a known finish composition.

FIG. 4 illustrates the improved abrasion resistance of a 60/40para-aramid/meta-aramid fabric treated with a finish compositionconsistent with the present invention as compared to a sample of thesame fabric treated with a known finish composition.

FIG. 5 illustrates the improved abrasion resistance of a 60/40para-aramid/meta-aramid fabric treated with a finish compositionconsistent with the present invention as compared to a sample of thesame fabric treated with a known finish composition and as compared to asample of a similar fabric that is commercially available.

FIG. 6 illustrates the improved abrasion resistance of a 60/40para-aramid/meta-aramid fabric treated with a finish compositionconsistent with the present invention as compared to a sample of thesame fabric treated with a known finish composition.

FIG. 7 illustrates the improved abrasion resistance of a 60/40para-aramid/PBI fabric treated with a finish composition consistent withthe present invention as compared to a sample of the same fabric treatedwith a known finish composition and as compared to a sample of a similarfabric that is commercially available.

FIG. 8 illustrates the improved pilling resistance of a 60/40para-aramid/meta-aramid fabric treated with a finish compositionconsistent with the present invention as compared to a sample of thesame fabric treated with a known finish composition.

FIG. 9. illustrates the improved pilling resistance of a 60/40para-aramid/PBO fabric treated with a finish composition consistent withthe present invention as compared to a sample of the same fabric treatedwith a known finish composition.

DETAILED DESCRIPTION OF THE INVENTION

One embodiment of the present invention provides fabrics that areresistant to abrasion and/or pilling. Abrasion tests were conducted onthese fabrics and prior art fabrics, and the fabrics consistent with thepresent invention had an abrasion resistance at least twice that offabrics treated with prior art formulations. For example, the fabrics ofthe present invention withstand at least 1000 cycles before the firstthread break according to ASTM D3884 Standard Test Method for AbrasionResistance of Textile Fabrics (Rotary Platform, Double-Head Method),using H-18 wheels and a 500 g load on each wheel. The abrasionresistance of the fabrics more preferably is 1500 cycles before thefirst break, and most preferably is 2500 cycles before the first break.Additionally or alternatively, these fabrics have a pilling performancerating of at least 4 after 60 minutes and a rating of at least 3 after90 minutes according to ASTM D3512 Standard Test Method for PillingResistance and Other Related Surface Changes of Textile Fabrics: RandomTumble Pilling Tester. More preferably the fabrics have a rating of atleast 4 after 90 minutes and a rating of at least 3 after 120 minutes.

In one embodiment, the fabric is a flame resistant fabric. The fabricpreferably has flame resistant properties which remain after the finishcomposition is applied. The fabric may further have water repellantproperties which also remain after the finish composition is applied.The fabric is intended to meet all flame resistance, thermal resistance,and water repellency requirements of one or more of the following: NFPA1951, NFPA 1971, NFPA 1977, NFPA 2112, NFPA 70E, and militaryspecifications MIL-C-83429B and GL-PD-07-12. For example, according toNFPA 1971 an outer shell fabric for firefighters must exhibit a charlength of less than or equal to 4.0 inches after flame exposure and thefabric must exhibit an afterflame of less than 2.0 seconds when testedin accordance with ASTM D6413.

Flammability of the fabrics of the present invention was testedaccording to ASTM D6413 Standard Test Method for Flame Resistance ofTextiles (Vertical Test). The fabrics exhibited a char length of no morethan 0.8 inches in the warp direction and 0.6 inches in the filldirection before laundering and a char length of no more than 0.6 inchesin the warp direction and 0.5 inches in the fill direction after fivelaunderings. The fabrics exhibited an afterflame of 0.0 seconds bothbefore laundering and after five launderings. The water repellantproperties of the fabrics were determined in accordance with AATCC TestMethod 22 Water Repellency: Spray Test and NFPA 1971, 8.26 WaterAbsorption Resistance Test. The fabrics have a water spray rating of 100before laundering and a water spray rating of at least 70 after fivelaunderings. The fabrics exhibited a water absorption of no more than1.0% before laundering and no more than 2.0% after five launderings.

The flame resistant fabric may be a fabric that has been treated with afinish composition according to an embodiment of the present invention.Suitable flame resistant fabrics include, but are not limited to,fabrics comprising inherently flame resistant fibers such as aramid(meta-aramid or para-aramid), polybenzimidazole (PBI), polybenzoxazole(PBO), melamine, polyimide, polyimideamide, modacrylic fibers, FR rayonand combinations thereof. Specific commercially available fiberssuitable for use with the present invention either alone or incombination with other fibers include KEVLAR® (a para-aramid), NOMEX® (ameta-aramid), TWARON® (a para-aramid), TECHNORA® (an aromaticco-polyamide), and ZYLON® (a polybenzoxazole). Other suitable fabricsinclude fabrics comprising non-inherently flame resistant fibers thathave been rendered flame resistant by treating such fibers with asuitable flame retardant. Such fibers include, but are not limited to,nylon, cellulosic fibers such as rayon, cotton, acetate, triacetate,lyocell, and combinations thereof. A suitable fabric may be a plainweave fabric or a fabric having another configuration such as, but notlimited to, rip-stop, twill weave, sateen weave, or knitted and theseconfigurations may be stretch or non-stretch. The flame resistant fabricmay additionally have water-resistant properties and/or may be treatedwith a water-resistant finish to prevent or reduce water absorption fromthe outside environment in which a garment constructed from the fabricmay be used.

Another embodiment of the present invention is a garment made from afabric that has been treated with a finish composition wherein thefinish composition improves the resistance of the fabric, and thereforethe resistance of the garment, to pilling and/or surface abrasion. Thegarment preferably has flame resistant properties which remain after thefinish composition is applied. The garment may further have waterrepellant properties which also remain after the finish composition isapplied.

Preferably, the majority of the fibers of the outer surface of theprotective garment of the present invention are constructed of a flameresistant material such as meta-aramid, para-aramid, flame resistantcellulosic materials (e.g. flame resistant cotton, rayon, or acetate),polybenzoxazole (PBO), or polybenzimidazole (PBI).

FIG. 1 illustrates an example of a protective garment 100 for which thefabric of this invention is particularly well-suited. The garment 100can be a firefighter turnout coat (shown in FIG. 1) or any other garmentor garment layer that is flame resistant and surface abrasion and/orpilling resistant as described herein. Although a turnout coat is usedas an example and explicitly discussed herein, a coat has beenidentified for purposes of example only. Accordingly, the presentinvention is not limited to firefighter turnout coats but insteadpertains to substantially any garments that may be worn by afirefighter, rescue worker, military, electrical worker, petrochemicalworker, or other individual to provide thermal or another type ofprotection. Such garments include but are not limited to shirts, pants,jackets, coveralls, vests, t-shirts, underwear, gloves, liners forgloves, hats, helmets, boots, and the like. The present invention is notlimited to garments, but can include other uses for flame resistant, andpilling and/or surface abrasion resistant fabrics irrespective of theirapplication.

The garment 100 shown in FIG. 1 includes an outer shell 102 that formsan exterior surface of the garment 100, a barrier layer 104 that formsan intermediate layer of the garment, and a thermal liner 106 that formsan interior surface of the garment 100. For general reference, theexterior surface or outer shell 102 can be directly exposed to theenvironment in which the user or wearer is operating, and the interiorsurface of the thermal liner 106 is a surface that contacts the user orwearer, or contacts the clothes the user or wearer may be wearing. Inaccordance with an embodiment of the invention, some or all of thelayers 102, 104, or 106 forming garment 100 can include the flameresistant, pilling and/or surface abrasion resistant fabrics of thisinvention.

Another embodiment of the present invention is a fabric finishcomposition capable of imparting abrasion and/or pilling resistance tofibers, fabrics, and garments. According to various embodiments of theinvention, a finish is capable of improving the resistance of thefibers, fabrics, or garments to surface abrasion and/or pilling.Preferably, the finish is capable of improving the surface abrasion andpilling resistance of a flame resistant and/or water resistant fabricwithout reducing the flame retardant or water resistant properties ofthe fabric. The application of the finish to the fabric can varydepending upon the desired physical properties of the treated fabric,the composition of the fabric, and the types of fibers or body yarnsselected for the fabric.

In some embodiments the finish composition of the present invention canimprove the after-wash appearance of certain fabrics containingpara-aramids by reducing the amount of fibrillation that occurs duringwashing

According to one embodiment of the invention, a suitable finish can be acombination of a polymeric cross-linking abrasion resistance aid, analkylfluoropolymer, a polyethylene, and a wetting agent.

According to other embodiments of the invention a suitable finish mayfurther include a combined sewing/abrasion polymeric aid, an alkoxylatedfatty amine or derivative thereof, a melamine formaldehyde resin orN-methylol stearamide, a flame retardant additive or combinationsthereof.

Examples of suitable polymeric cross-linking abrasion resistance aidsinclude, but are not limited to, urethane-based polymers, such asEccorez FRU-33 (a hydrophobic urethane polymer available from EasternColor and Chemical); abrasion resistant polymer/perfluoroalkylcontaining polymer blends such as Hipel 340 (a proprietary blend ofabrasion aid polymers and a perfluoroalkyl containing polymer availablefrom Hi-Tech Chemicals) and Ridgepel 34 (a blendedurethane/perfluoroalkyl product available from Blue Ridge Products); andacrylic polymers such as FDP-61063 (a self cross-linking acrylicco-polymer with a Tg of +25° C., available from Omnova Solutions) andDicrylan TA-GP (a self cross-linking ethylacrylate polymer with a Tg of−14° C., available from Huntsman Chemical). Suitable perfluoroalkylcontaining polymers include, but are not limited to, UNIDYNE® TG 580 (anon-ionic C8 perfluoroalkyl polymer available from Daikin America),UNIDYNE® TG 581 (a cationic fluoropolymer available from DaikinAmerica), Rainoff F-8 (a perfluoroalkyl polymer available from EasternColor and Chemical), and the above mentioned blends ofalkylfluoropolymers and abrasion aid polymers, Hipel 340 and Ridgepel34. Suitable polyethylenes include, but are not limited to, medium andhigh density polyethylenes. Suitable wetting agents include, but are notlimited to, Ridgewet NRW (previously called Genwet NRW and availablefrom Blue Ridge Products). Suitable sewing/abrasion polymeric aidsinclude, but are not limited to, medium to high density polyethyleneemulsions such as Aquasoft 706 (available from Apollo Chemicals, WareShoals, S.C.). Suitable alkoxylated fatty amines or derivatives thereofinclude, but are not limited to, Cartafix U (an alkoxylated fatty aminederivative product designed to inhibit finish migration and minimize padroll build up, available from Clariant). Suitable melamine formaldehyderesins include, but are not limited to, Aerotex M3 (manufactured byCytec Industries and available from Emerald Carolina Chemicals,Charlotte, N.C.) and Eccoresin M300 (available from Eastern Color andChemical). Suitable N-methylol stearamides include, but are not limitedto, Aurapel 330 (available from Star Chemicals). Suitable flameretardant additives include, but are not limited to, Amgard CT (a cyclicphosphate flame retardant additive, available from Rhodia).

In another embodiment of the present invention, a finishing process canbe used to apply a finish to fibers, yarns, fabrics, or garments. In apreferred embodiment the finishing process is used to apply a finish toa protective fabric. The following process is described by way ofexample, and other process embodiments in accordance with the inventioncan have fewer or greater numbers of steps, and may be practiced inalternative sequences. A protective fabric comprising a plurality offlame resistant fibers is received for treatment. At this point theprotective fabric may be substantially untreated or may be treated witha flame resistant, water resistant, or other composition, but isreferred to here as “untreated” to distinguish it from the fabric astreated according to a method of the present invention. A finishcomposition as described above and consistent with the present inventionis applied to the untreated protective fabric. The finish is cured bycontrolling at least one of the following: heat, pressure, or time. Thefabric treated by this process has improved resistance to surfaceabrasion and/or pilling.

Alternatively, a finish composition according to the present inventioncan impart abrasion and/or pilling resistance to a fabric when thatfinish composition is added to another finish composition that isapplied to the fabric. For example, a finish composition according tothe present invention and comprising a polymeric abrasion aid, fattyamine or derivative thereof, a polyethylene, and optionally one or moreof a sewing/abrasion polymeric aid, a crosslinking melamine formaldehyderesin, and a N-methylol stearamide could be added to a known finishcomposition such as, but not limited to, a moisture management finish, adurable press finish, or an antimicrobial finish. The combination offinishes would then impart a variety of advantageous properties,depending on the finishes used, including abrasion and/or pillingresistance.

In one embodiment, the untreated protective fabric is formed of aplurality of flame resistant fibers, such as the aramid,polybenzimidazole (PBI), polybenzoxazole (PBO), melamine, or otherfibers described above.

A variety of methodologies and associated devices can be used to applythe finish to the untreated protective fabric. These methodologiesinclude, but are not limited to, spray application, padding, rollcoating, applying a foam finish, and combinations thereof.

In some embodiments, the finish can be cured by applying heat and/orpressure over time to the untreated protective fabric, the finish, orboth, until one or more components of the finish are affected. In suchinstances curing may activate a particular finish component, createcross-linking with the fabric, or otherwise substantially adhere thefinish to the untreated protective fabric, while removing any excessmoisture that may exist in the untreated protective fabric and/orfinish. By way of example but not limitation, a suitable curing processcan be an oven drying process to apply heat to the initially treatedfabric and finish for approximately 1 to 5 minutes at between about 300and about 400° F.

EXAMPLES

The present invention is further illustrated by the following exampleswhich illustrate specific embodiments of the invention but are not meantto limit the invention.

Fabrics and Finishes

Examples of various fabrics that have been treated with finishcompositions consistent with the present invention are described inTable I. The fabrics are all woven protective fabrics comprisingring-spun yarns. Fabrics 1-3 are fire service outershell fabrics,fabrics 4 and 5 are fire service outershell fabrics that contain PBO,and fabric 6 is a military protective fabric.

TABLE I EXAMPLE FABRICS FOR USE WITH THE PRESENT INVENTION Fabric YarnWeave Finished weight 1 60% KEVLAR T-970 Rip Stop 7.7 osy 40% PBI 2 60%KEVLAR T-970 Rip Stop 7.5 osy 40% NOMEX T-462 3 60% KEVLAR T-970 Plainw/ 7.7 osy 40% PBI single rip 4 60% KEVLAR 2 End Rip Stop 7.5 osy 20%NOMEX T-462 20% ZYLON 5 60% TECHNORA Rip Stop 7.5 osy 40% ZYLON 6 65% FRRayon Rip Stop 6.2 osy 25% TWARON 10% Nylon

Various finish compositions consistent with the present invention aredescribed in Table II. These finish compositions include variouscombinations of (a) Ridgewet NRW (previously called Genwet NRW), anon-rewetting surfactant for improved fabric penetration; (b) Hipel 340,a proprietary blend of abrasion aid polymers and a perfluoroalkylcontaining polymer; (c) FDP-61063, a self cross-linking acrylicco-polymer; (d) Dicrylan TA-GP, a self cross-linking ethyl acrylatepolymer; (e) Unidyne TG580, a non-ionic fluoropolymer, (f) UnidyneTG581, a cationic fluoropolymer; (g) Cartafix U, an alkoxylated fattyamine derivative; (h) Aerotex M3 or Eccoresin M300, both melamineformaldehyde cross-linking resins; (i) Diammonium Phosphate, a catalystto promote self-crosslinking of melamine formaldehyde resin; (j)Aquasoft 706, a polyethylene emulsion emulsified with DA6; (k) Aurapel330R, an N-methylol stearamide reactive hydrophobe; and (1) AmgardCT, acyclic phosphonate flame retardant additive. All amounts are listed aspercent on weight of bath (owb).

Table II also includes a known finish composition, SST. This compositionincludes Ridgewet NRW, Eccoresin M300, diammonium phosphate, (m) Zonyl7040 and (n) Zonyl FMX (fluoropolymers available from Huntsman andmanufactured by DuPont), and (o) Phobotex JVA (an emulsion of paraffinwax, available from Huntsman).

TABLE II EXAMPLE FINISH COMPOSITIONS I II III IV V VI SST (a) Ridgewetwetting agent 0.5 0.5 0.5 0.5 0.25 0.15 0.25 NRW (b) Hipel 340proprietary abrasion aid 31.25 40.0 20-30 40.0 polymer/perfluoroalkylpolymer blend (c) FDP-61063 acrylic polymer 12.0 (d) Dicrylan acrylicpolymer 15.0 TAGP (e) Unidyne perfluoroalkyl polymer 28.0 TG580 (f)Unidyne perfluoroalkyl polymer 28.0 TG581 (g) Cartafix U alkoxylatedfatty amine 0.1 derivative (h) Aerotex melamine formaldehyde 2 3 1.96M3/Eccoresin resin M300 (i) Diammonium crosslinking agent 0.04 0.060.0446 Phosphate (j) Aquasoft polyethylene emulsion 2 4 4   4.0 5.0 5.0706 (k) Aurapel N-methylol stearamide 5-8 330R (l) AmgardCT flameretardant 0.5 0.75 (m) Zonyl 7040 perfluoroalkyl polymer 10 (n) ZonylFMX perfluoroalkyl polymer 20 blend (o) Phobotex paraffin wax/melamine10 JVA resin *all numbers are percent on weight of bath with theremainder of the compositions water.

Finish compositions were used to treat Fabrics 1-5. Finish I was used totreat Fabrics 1, 2, and 3. Finish II was used to treat Fabrics 4 and 5.And Finish III was used to treat Fabric 6. In each example the finishwas applied in a dip finish pad. The finish was then dried and cured.Fabrics 1-5 were dried and cured at 300-400° F. for 1-5 minutes. Fabric6 was dried and cured at 280-350° F. for 1-5 minutes. The treatedfabrics have improved abrasion and pilling resistance over untreatedfabrics. The improved abrasion and pilling resistance is retained for atleast 5-10 launderings. The treated fabrics retained the water repellentproperties and flame resistant properties of untreated fabric and showeddramatically improved resistance to abrasion and pilling over fabricstreated with prior art finishes as measured by standard ASTM testmethods such as Random Tumble Pilling and Taber Abrasion. In theexamples and data that follow, the fabrics have compositions shown inTable I and were treated with finish compositions as shown in Table IIor were treated with the prior art finish SST.

Test Methods

Abrasion resistance was measured in accordance with ASTM D3884 (2007),Standard Test Method for Abrasion Resistance of Textile Fabrics (RotaryPlatform Double-Head Method), the disclosure of which is herebyincorporated by reference, using H-18 wheels and a 500 g load on eachwheel.

Pilling resistance was measured in accordance with ASTM D3512-05(Reapproved 2007), Standard Test Method for Pilling Resistance and OtherRelated Surface Changes of Textile Fabrics: Random Tumble Pilling TesterMethod, the disclosure of which is hereby incorporated by reference.

Tensile strength was measured in accordance with ASTM D5034 StandardTest Method for Breaking Strength and Elongation of Textile Fabrics(Grab Test), the disclosure of which is hereby incorporated byreference.

Tear strength was measured in accordance with ASTM D5733 Standard TestMethod for Tearing Strength of Nonwoven Fabrics by the TrapezoidProcedure, the disclosure of which is hereby incorporated by reference.

Vertical flammability was measured in accordance with ASTM D6413Standard Test Method for Flame Resistance of Textiles (Vertical Test),the disclosure of which is hereby incorporated by reference.

Water spray rating was measured in accordance with AATCC Test Method 22(2005) (AATCC Technical Manual) Water Repellency: Spray Test, thedisclosure of which is hereby incorporated by reference.

Water absorption resistance was measured in accordance with NFPA 1971(2007) Protective Ensembles for Structural Fire Fighting and ProximityFire Fighting, 8.26 Water Absorption Resistance Test, the disclosure ofwhich is hereby incorporated by reference.

Air permeability was measured in accordance with Federal Test Method5450.1 Permeability to Air; Cloth, Calibrated Orifice Method, thedisclosure of which is hereby incorporated by reference.

The fabric samples were tested either before they were washed (BW),after 5 launderings (5×), or after 10 launderings (10×). All launderingswere in accordance with AATCC Test Method 135 2006), Dimensional Changesof Fabrics after Home Laundering. Specifically, specimens are subjectedto washing and drying in accordance with Machine Cycle 1: normal/cottonsturdy cycle; Washing Temperature V: 60±3° C. (140±5° F.); WashingMachine Conditions: Normal cycle with water level of 18±1 gal, agitatorspeed of 179±2 spm, washing time of 12 min, spin speed of 645±15 rpm andfinal spin time of 6 min; and Dryer Setting Conditions: cotton/sturdycycle with high exhaust temperature (66±5° C., 150±10° F.) and a cooldown time of 10 min.

The standards for flame resistance that are referred to herein are NFPA1951 2007), Standard on Protective Ensembles for Technical RescueIncidents; NFPA 1971 (2007), Standard on Protective Ensembles forStructural Fire Fighting and Proximity Fire Fighting; NFPA 1977 (2005),Standard on Protective Clothing and Equipment for Wildlands FireFighting; NFPA 2112 (2007), Standard on Flame-Resistant Garments forProtection of Industrial Personnel Against Flash Fire; NFPA 70E Standardfor Electrical Safety Requirements for Employee Workplaces; and militaryspecifications MIL-C-83429B and GL-PD-07-12, the disclosures of whichare hereby incorporated by reference.

Experimental

Samples of Fabric 2 in Table I were treated with fabric finishesaccording to embodiments of the present invention (specifically finishcompositions II and IV-VI from Table II) or the prior art finish, SST.Each fabric sample was subjected to a standard Taber abrasion test inaccordance with ASTM D3884, using H-18 wheels and a 500 g load on eachwheel. According to this method a specimen is abraded using rotaryrubbing action under controlled conditions of pressure and abrasiveaction. The test specimen, mounted on a platform, turns on a verticalaxis against the sliding rotation of two abrading wheels. One abradingwheel rubs the specimen outward toward the periphery and the otherinward toward the center. The resulting abrasion marks form a pattern ofcrossed arcs over an area of approximately 30 cm².

Each fabric sample was subjected to 250 cycles and then was inspectedfor thread break. If no thread break was observed the fabric sample wassubjected to 250 additional cycles and was inspected again. This processcontinued for each fabric sample until a thread break was observed forthat sample. The results of the abrasion resistance tests are shown inTable III, below. The fabric samples treated with embodiments of thepresent invention withstood more cycles before breaking than the fabricsamples treated with the prior art finish composition. These data showan improvement in abrasion resistance of at least about 100% over thefabric samples treated with the prior art composition.

TABLE III ABRASION RESISTANCE Taber cycles to first break (10× samples)Fabric Finish Sample 1 Sample 2 Sample 3 Average A 2 SST 500 500 500 500B 2 II 1250 1000 1250 1167 C 2 IV 1750 2000 1600 1783 D 2 V 2500 20001500 2000 E 2 VI 2000 1000 1750 1583 *samples run in increments of 250cycles and inspected for yarn break

Samples of Fabric 4 in Table I were treated with fabric finishesaccording to embodiments of the present invention (specifically finishcompositions II and IV-VI from Table II) or the prior art finish, SST,and were subjected to tests to determine resistance to pilling. Eachfabric sample was subjected to a standard pilling resistance test inaccordance with ASTM D3512. According to test method D3512 a specimen isconditioned in an environment chamber and then tumbled in cork linedcylinders with cotton sliver. Bias cut replicates are tested forpredetermined times. Samples are evaluated using the photographic ratingstandards in the Macbeth Light Booth (daylight conditions). A rating of1 indicates very severe pilling while a rating of 5 represents nopilling. The samples were tested for 60, 90, and 120 minutes. Theresults of these tests are shown in Table IV, below. The fabrics treatedwith embodiments of the present invention showed improved resistance topilling over fabrics treated with the prior art SST finish composition.

TABLE IV PILLING RESISTANCE Fabric Finish 60 min 90 min 120 min D 4 SST1 1 1 G 4 II 4 3 2-3 H 4 IV 4 3-4 3 I 4 V 2 2 2 J 4 VI 4 3-4 3

Samples of Fabrics 2 and 4 in Table I were treated with fabric finishesaccording to embodiments of the present invention (specifically finishcompositions II and IV-VI from Table II) or the prior art finish, SST,and were subjected to a variety of tests to determine tensile strength,tear strength, flame resistance, water repellency, and air permeability.

Tensile strength is the force required to break a fabric under a load.The fabric samples were subjected to a standard tensile test inaccordance with ASTM D5034. According to this method a specimen ismounted centrally in clamps of a tensile machine and a force is applieduntil the specimen breaks. Values for the breaking force and theelongation of the test specimen are obtained from machine scales, dials,autographic recording charts, or a computer interfaced with the testingmachine. The tensile strength of each fabric was tested in the warpdirection (w) and in the fill direction (f). The results of these testsare shown in Table V below. Based on these results, the finishcomposition according to the present invention has no adverse impact onthe tensile strength of the fabrics.

TABLE V TENSILE STRENGTH Fabric Finish BW (lbs/in) (w × f) 5x (lbs/in)(w × f) 10x (lbs/in) (w × f) A 2 SST 307.4 × 294.7 271.8 × 223.2 272.7 ×223.8 B 2 II 341.0 × 315.0 317.0 × 265.9 304.8 × 250.0 C 2 IV 336.1 ×290.0 310.4 × 280.7 326.5 × 269.7 D 2 V 316.9 × 299.3 308.1 × 259.8295.5 × 247.0 E 2 VI 325.7 × 284.6 334.9 × 267.4 322.1 × 283.7 F 4 SST452.7 × 401.5 411.3 × 384.8 400.0 × 358.4 G 4 II 489.4 × 420.7 465.5 ×446.0 427.1 × 400.0 H 4 IV 471.2 × 395.3 467.2 × 417.1 417.6 × 424.0 I 4V 452.5 × 411.8 448.0 × 403.0 392.8 × 389.6 J 4 VI 449.5 × 399.4 452.6 ×421.7 405.7 × 398.0

Tear strength is the force required either to start or to continue orpropagate a tear in a fabric. Each fabric sample was also subjected to astandard tear strength test in accordance with ASTM D5733. According tothis method an outline of an isosceles trapezoid is marked on arectangular specimen cut for the determination of tearing strength. Thespecimen is slit at the center of the smallest base of the trapezoid tostart the tear. The nonparallel sides of the trapezoid marked on thespecimen are clamped in parallel jaws of a tensile testing machine. Theseparation of the jaws is continuously increased to apply a force topropagate the tear across the specimen. At the same time, the forcedeveloped is recorded. The maximum force to continue the tear iscalculated from autographic chart recorders, or microprocessor datacollection systems. Tear strength of each fabric was determined in thewarp direction (w) and in the fill direction (f). The results of thesetests are shown in Table VI below. Based on these results, the finishcomposition according to the present invention has no adverse impact onthe tear strength of the fabric.

TABLE VI TEAR STRENGTH Fabric Finish BW (lbs/in) (w × f) 5x (lbs/in) (w× f) 10x (lbs/in) (w × f) A 2 SST 52.1 × 40.4 40.1 × 33.2 36.9 × 36.3 B2 II 52.5 × 36.5 46.1 × 35.3 42.4 × 32.8 C 2 IV 49.8 × 37.4 47.7 × 37.544.7 × 34.2 D 2 V 46.4 × 33.3 44.0 × 32.7 40.5 × 30.5 E 2 VI 46.3 × 34.846.0 × 36.6 44.0 × 35.7 F 4 SST 52.5 × 50.1 48.8 × 44.2 44.1 × 39.7 G 4II 57.1 × 47.2 55.2 × 47.3 50.4 × 49.0 H 4 IV 55.5 × 51.7 56.1 × 50.952.2 × 49.0 I 4 V 56.0 × 44.5 53.4 × 42.4 50.0 × 37.8 J 4 VI 54.6 × 44.853.4 × 46.0 47.3 × 40.7

The flame resistant properties of the fabrics were tested according toASTM D6413. According to this method a fabric is hung vertically andexposed to an open flame. The char length and afterflame are determinedfor each fabric. The char length for each fabric was determined in thewarp direction (w) and in the fill direction (f). The results of thistest for the fabrics described herein are shown in Table VII below.Based on these results, the finish composition according to the presentinvention has no adverse impact on the flame resistant properties of thefabric.

TABLE VII VERTICAL FLAMMABILITY Char Length After Flame (in) wxf (sec)wxf Sample Fabric Finish BW 5x BW 5x A 2 SST 0.6 × 0.5 0.5 × 0.4 0.0 0.0B 2 II 0.7 × 0.6 0.4 × 0.4 0.0 0.0 C 2 IV 0.8 × 0.6 0.6 × 0.5 0.0 0.0 D2 V 0.8 × 0.6 0.5 × 0.4 0.0 0.0 E 2 VI 0.8 × 0.6 0.6 × 0.5 0.0 0.0 F 4SST 0.1 × 0.1 0.1 × 0.1 0.0 0.0 G 4 II 0.1 × 0.1 0.1 × 0.1 0.0 0.0 H 4IV 0.1 × 0.1 0.1 × 0.1 0.0 0.0 I 4 V 0.1 × 0.0 0.1 × 0.0 0.0 0.0 J 4 VI0.1 × 0.1 0.1 × 0.1 0.0 0.0

The water resistance of the fabrics was determined using AATCC testmethod 22 and NFPA 1971, 8.26. According to AATCC test method 22, wateris sprayed against a taut surface of a test specimen under controlledconditions and produces a wetted pattern whose size depends on therepellency of the fabric. Evaluation is accomplished by comparing thewetted pattern with pictures on a standard chart. According to NFPA1971, 8.26, a specimen is mounted to an embroidery hoop and a volume ofwater is allowed to spray onto the specimen. Blotting paper is used toremove excess water and a 4 in×4 in square is cut from the sample. Thewet sample is weighed, dried, and weighed again. The percent waterabsorption (PWA) is determined based on the difference in the wet anddry weights. The results for both of these tests are shown in Table VIIIbelow. Based on these results the finish compositions of the presentinvention do not affect the water repellent properties of the fabric andthese fabrics pass the requirements of water resistance of NFPA 1971.

The permeability to air of the fabrics was determined using Federal TestMethod 5450.1. According to this method, a specimen is clamped intoposition across a cloth orifice at a slight tension and in a smoothcondition. Air is drawn through the cloth and through the calibratedorifice by means of a suction fan. The pressure drop across the cloth isadjusted to the required pressure drop by adjusting the speed of the fanmotor. The volume of air passing through the cloth is calculated fromthis value and the calibration of the orifice. The results of this testare shown in Table VIII below. Based on these results the finishcompositions of the present invention do not affect the air permeabilityproperties of the fabrics and that these fabrics pass the requirementsof air permeability of NFPA 1971.

TABLE VIII WATER SPRAY/ABSORPTION AND AIR PERMEABILITY Water Water SprayAbsorption Air (rating) (%) Permeability Sample Fabric Finish BW 5x BW5x (ft³/min/ft²) A 2 SST 100 70 .04 0 19.6 B 2 II 100 70 .04 1.3 19.1 C2 IV 100 80 0.7 0 17.5 D 2 V 100 90 0.3 2.0 18.6 E 2 VI 100 90 0.7 1.018.3 F 4 SST 100 80 0.3 2.0 6.4 G 4 II 100 100 1 1.3 19.2 H 4 IV 100 1001 1 18.5 I 4 V 100 95 0.7 1.6 18.6 J 4 VI 100 95 0.5 1.0 22.8

The samples depicted in FIGS. 2-7 were subjected to the ASTM D3884 testfor abrasion resistance using H-18 wheels and a 500 g load on eachwheel, which was described previously.

FIG. 2 depicts two samples of Fabric 1 from Table I. The fabric sampleon the left was treated with finish composition I as described in TableII. The fabric sample on the right was treated with the SST finishcomposition described in Table II. The abrasion resistance of bothfabric samples was tested in accordance with the ASTM standard describedabove. The fabric samples were not laundered prior to testing. Thefabric sample treated according to an embodiment of the presentinvention shows improved abrasion resistance over the fabric sampletreated with the known finish composition.

FIG. 3 depicts two samples of Fabric 1 from Table I. The fabric sampleon the left was treated with finish composition I as described in TableII. The fabric sample on the right was treated with the SST finishcomposition. The abrasion resistance of both fabrics was tested inaccordance with the ASTM standard described above. The fabric sampleswere laundered 10 times prior to testing. The fabric sample treatedaccording to an embodiment of the present invention shows improvedabrasion resistance over the fabric sample treated with the known finishcomposition.

FIG. 4 depicts two samples of Fabric 2 from Table I. The fabric sampleon the left was treated with finish composition I as described in TableII. The fabric sample on the right was treated with the SST finishcomposition. The abrasion resistance of both fabric samples was testedin accordance with the ASTM standard described above. The fabric sampleswere not laundered prior to testing. The fabric sample treated accordingto an embodiment of the present invention shows improved abrasionresistance over the fabric sample treated with the known finishcomposition.

FIG. 5 depicts two samples of Fabric 2 from Table I and one sample ofFusion fabric available from Safety Components. The fabric samples onthe left and in the middle are Fabric 2 from Table I and the fabricsample on the right is Fusion. Fusion is a 50/50 p-aramid/m-aramid blendfabric. The sample of Fabric 2 on the far left was treated with finishcomposition I as described in Table II. The sample of Fabric 2 shown inthe middle was treated with the SST finish composition. The abrasionresistance of the three fabric samples was tested in accordance with theASTM standard described above. The fabric samples were laundered 5 timesprior to testing. The fabric sample on the far left, which was treatedaccording to an embodiment of the present invention, shows improvedabrasion resistance over the fabric sample treated with the SST finishcomposition and the Fusion fabric.

FIG. 6 depicts two samples of Fabric 2 from Table I. The fabric sampleon the left was treated with finish composition I as described in TableII. The fabric sample on the right was treated with the SST finishcomposition. The abrasion resistance of both fabric samples was testedin accordance with the ASTM standard described above. The fabric sampleswere laundered 10 times prior to testing. The fabric sample treatedaccording to an embodiment of the present invention shows improvedabrasion resistance over the fabric sample treated with the known finishcomposition.

FIG. 7 depicts two samples of Fabric 3 from Table I and one sample ofMatrix fabric, available from Safety Components. The fabric samples onthe left and in the middle are Fabric 3 from Table I and the fabricsample on the right is Matrix. Matrix fabric is a 60/40 p-aramid/PBIfabric. The sample of Fabric 3 on the left was treated with finishcomposition I as described in Table II. The sample of Fabric 3 in themiddle was treated with the SST finish composition. The abrasionresistance of the three fabric samples was tested in accordance with theASTM standard described above. The fabric samples were laundered 5 timesprior to testing. The fabric sample on the left, which was treatedaccording to an embodiment of the present invention, shows improvedabrasion resistance over the fabric sample treated with the SST finishcomposition and the Matrix fabric.

The samples depicted in FIGS. 8 and 9 were subjected to the ASTM D3512test for pilling resistance, which was described previously.

FIG. 8 depicts two samples of Fabric 2 from Table I. The fabric sampleon the left was treated with finish composition I as described in TableII. The fabric sample on the right was treated with the SST finishcomposition. The pilling resistance of both fabric samples was tested inaccordance with the ASTM standard described above. The fabric sampleswere not laundered prior to testing. The fabric sample treated accordingto an embodiment of the present invention shows improved pillingresistance over the fabric sample treated with the known finishcomposition.

FIG. 9 depicts two samples of Fabric 5 from Table I. The fabric sampleon the bottom was treated with finish composition I as described inTable II. The fabric sample on top was treated with the SST finishcomposition. The pilling resistance of both fabric samples was tested inaccordance with the ASTM standard described above. The fabric sampleswere laundered 10 times prior to testing. The fabric sample treatedaccording to an embodiment of the present invention shows improvedpilling resistance over the fabric sample treated with the known finishcomposition.

The foregoing is provided for purposes of illustrating, explaining, anddescribing exemplary embodiments and certain benefits of the presentinvention. Modifications and adaptations to the illustrated anddescribed embodiments will be apparent to those skilled in the art andmay be made without departing from the scope or spirit of the invention.

The invention claimed is:
 1. A flame resistant fabric, comprising: aplurality of spun yarns comprising a plurality of flame resistantfibers; and a finish that imparts abrasion resistance to the fabric, thefinish comprising a polymeric abrasion resistance aid and a hydrophobiccomponent, wherein the fabric, before laundering and after beinglaundered five times in accordance with AATCC test method 135 (2006),has an abrasion resistance of at least about 1000 cycles before a firstthread break when tested in accordance with ASTM test method D3884(2007) (H-18, 500 g on each wheel).
 2. The flame resistant fabric ofclaim 1, wherein the finish further comprises at least one of a durablepress component and an antimicrobial component.
 3. The flame resistantfabric of claim 1, wherein the polymeric abrasion resistance aidcomprises an acrylic polymer.
 4. The flame resistant fabric of claim 1,wherein the finish further comprises at least one of an alkoxylatedfatty amine or derivative thereof, a melamine formaldehyde resin, anN-methylol stearamide, or combinations thereof.
 5. The flame resistantfabric of claim 1, wherein at least some of the plurality of flameresistant fibers are inherently flame resistant fibers comprising atleast one of meta-aramid fibers, para-aramid fibers, polybenzimidazolefibers, polybenzoxazole fibers, melamine fibers, polyimide fibers,polyimideamide fibers, modacrylic fibers, and FR rayon fibers.
 6. Theflame resistant fabric of claim 1, wherein the abrasion resistance is atleast about 1500 cycles before the first thread break.
 7. The flameresistant fabric of claim 6, wherein the abrasion resistance is at leastabout 2500 cycles before the first thread break.
 8. The flame resistantfabric of claim 1, wherein the fabric, before laundering and after beinglaundered five times in accordance with AATCC test method 135 (2006),meets all flammability requirements of one or more of NFPA 1951 (2007),NFPA 1971 (2007), NFPA 1977 (2005), NFPA 2112 (2007), militaryspecification MIL-C-83429B, or military specification GL-PD-07-12. 9.The flame resistant fabric of claim 1, wherein the fabric, after beinglaundered ten times in accordance with AATCC test method 135 (2006),meets all flammability requirements of one or more of NFPA 1951 (2007),NFPA 1971 (2007), NFPA 1977 (2005), NFPA 2112 (2007), militaryspecification MIL-C-83429B, or military specification GL-PD-07-12. 10.The flame resistant fabric of claim 1, wherein the fabric, beforelaundering and after being laundered five times in accordance with AATCCtest method 135 (2006), meets all water repellency requirements of oneor both of NFPA 1951 (2007) or NFPA 1971 (2007).
 11. The flame resistantfabric of claim 1, wherein the fabric, after being laundered ten timesin accordance with AATCC test method 135 (2006), meets all waterrepellency requirements of one or both of NFPA 1951 (2007) or NFPA 1971(2007).
 12. The flame resistant fabric of claim 1, wherein the fabric,before laundering and after being laundered five times in accordancewith AATCC test method 135 (2006), has water repellant propertiescomprising a water spray rating of at least about 70 as determined byAATCC test method 22 (2005) and a water absorption of less than or equalto about 2.0% as determined by NFPA 1971, 8.26 (2007).
 13. The flameresistant fabric of claim 12, wherein the water spray rating is about100 as determined by AATCC test method 22 (2005) and the waterabsorption is less than or equal to about 1.0% as determined by NFPA1971, 8.26 (2007).
 14. The flame resistant fabric of claim 1, whereinthe fabric has a pilling performance rating of at least 4 after 60minutes and a rating of at least 3 after 90 minutes when tested inaccordance with ASTM test method D3512-05 (Reapproved 2007).
 15. Theflame resistant fabric of claim 14, wherein the pilling performancerating is at least 4 after 90 minutes and at least 3 after 120 minutes.16. The flame resistant fabric of claim 1, wherein the fabric meets airpermeability requirements in accordance with NFPA 1971 (2007).
 17. Theflame resistant fabric of claim 1, wherein the fabric comprises a plainweave, a rip-stop, a twill weave, sateen weave or knitted fabric andwherein the fabric is stretch or non-stretch.
 18. The flame resistantfabric of claim 1, wherein the fabric has a weight of less than about8.0 osy.
 19. A flame resistant garment comprising the flame resistantfabric of claim
 1. 20. A flame resistant fabric, comprising: a pluralityof spun yarns comprising a plurality of flame resistant fibers; and afinish that imparts abrasion resistance to the fabric, the finishcomprising a polymeric abrasion resistance aid and at least one of amoisture management component, a durable press component, and anantimicrobial component, wherein the fabric, before laundering and afterbeing laundered five times in accordance with AATCC test method 135(2006), has an abrasion resistance of at least about 1000 cycles beforea first thread break when tested in accordance with ASTM test methodD3884 (2007) (H-18, 500 g on each wheel).